Power connector with integrated power monitoring

ABSTRACT

An electronic power connector including a contact configured to electrically connect a power supply to a load. The electronic power connector further including a contact core configured to receive the contact, the contact core including a transformer winding wrapped around the contact core, the transformer winding configured to sense a current

RELATED APPLICATIONS

The present application claims priority to U.S. patent application Ser.No. 16/423,542, filed on May 28, 2019, which claims priority to U.S.patent application Ser. No. 15/592,927, filed May 11, 2017, which claimspriority to U.S. Provisional Application 62/334,872, filed May 11, 2016,the entire contents both of which are hereby incorporated.

FIELD

Embodiments relate to electrical power connectors.

SUMMARY

Electrical power connectors provide a connection between a power supplyand a load. Such electrical power connectors may be described in U.S.patent application Ser. No. 15/072,672, filed Mar. 17, 2016, which ishereby incorporated by reference.

Power measurements are typically used to monitor the power consumptionof the equipment connected through an electrical power connector. Insome cases, the ability to accurately measure the power consumptionenables an operator to allocate energy costs to various users based onthe usage of the equipment.

Environmental monitoring, in particular temperature, can be used toidentify normal versus abnormal operating conditions. Continuousmeasurement enables identification of changes in operating parametersthat are out of acceptable ranges so that an alert is triggered tonotify the operators to the condition. In the absence of thiscapability, users may monitor connection temperature by regular manualscanning of the temperature. Furthermore, data analytics andunderstanding the normal operating parameters help provide the user withpredictive, or preventive, alerts before a potential failure occurs dueto environmental or installation anomalies.

In one embodiment, the application provides an electrical powerconnector including a contact and a contact core. The contact isconfigured to electrically connect a power supply to a load. The contactcore is configured to receive the contact. The contact core includes atransformer winding configured to sense a current and a sensor slotconfigured to receive a sensor. In some embodiments, the sensor isconfigured to sense a temperature. In some embodiments, the sensor isconfigured to sense a voltage.

In another embodiment, the application provides a power connectorincluding a sleeve and a contact carrier located within the sleeve. Thecontact carrier includes a contact transformer module having a connectorcontact, a contact core, and a transformer winding.

In yet another embodiment, the application provides a method of sensingvarious characteristics of an electronic power connector. The methodincluding providing a transformer winding around a contact core;providing a sensor slot proximate the contact core, the sensor slotconfigured to receive a sensor; sensing, via the transformer, a current;and sensing, via the sensor, a characteristic.

Other aspects of the application will become apparent by considerationof the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a power system according to one embodimentof the application.

FIG. 2 is a perspective view of an electrical power connector of thepower system of FIG. 1 according to some embodiments of the application.

FIG. 3 is a break away view of a contact carrier of the electrical powerconnector of FIG. 2 according to some embodiments of the application.

FIG. 4 is a perspective view of a contact carrier of the electricalpower connector of FIG. 2 according to some embodiments of theapplication.

FIG. 5 is a partially exposed view of the contact carrier of FIG. 4according to some embodiments of the application.

FIG. 6 is a cutaway view of the contact carrier of FIG. 4 according tosome embodiments of the application.

FIG. 7 is a top view of the contact carrier of FIG. 4 according to someembodiments of the application.

FIG. 8 is a perspective view of a contact transformer module of thecontact carrier of FIG. 4 according to some embodiments of theapplication.

FIG. 9 is another perspective view of the contact transformer module ofFIG. 8 according to some embodiments of the application.

FIG. 10 is a top view of the contact transformer module of FIG. 8according to some embodiments of the application.

FIG. 11 is a perspective view of the contact transformer module of FIG.8 without a contact, according to some embodiments of the application.

FIG. 12 is a side perspective view of the contact transformer module ofFIG. 11 according to some embodiments of the application.

FIG. 13 is a perspective view of the contact transformer module of FIG.8 including a shield, according to some embodiments of the application.

FIG. 14 is a front perspective view of the contact carrier of FIG. 4without a cover, according to some embodiments of the application.

FIG. 15 is a front perspective view of the contact carrier of FIG. 4without a cover, according to some embodiments of the application.

FIG. 16 is a top view of a transformer winding according to anotherembodiment of the application.

FIG. 17 is a top view of a contact carrier including the transformer ofFIG. 17 according to an embodiment of the application.

DETAILED DESCRIPTION

Before any embodiments of the application are explained in detail, it isto be understood that the application is not limited in its applicationto the details of construction and the arrangement of components setforth in the following description or illustrated in the followingdrawings. The application is capable of other embodiments and of beingpracticed or of being carried out in various ways.

FIG. 1 illustrates a power system 100 according to some embodiments ofthe application. The power system 100 includes a power supply 105, aload 110, an electrical power connector, or connector, 115, and a powersupply cable 120. In some embodiments, the power supply 105 is asingle-phase power supply outputting a voltage within a range ofapproximately 100 VAC to approximately 240 VAC. In other embodiments,the powers supply 105 is a three-phase power supply outputting a voltagewithin a range of approximately 208 VAC to approximately 600 VAC. Theload 110 may be any electrical device or system configured to receivepower.

FIG. 2 illustrates the connector 115 according to an embodiment of theapplication. The electrical power connector 115 is configured to providean electrical connection between the power supply 105 and the load 110.The connector 115 may be configured to handle twenty-amps, thirty-amps,sixty-amps, one-hundred amps, etc. As illustrated, the connector 115includes a contact carrier 200 and a sleeve connector 205. The contactcarrier 200 includes one or more power terminals 210 located on a firstend 215 of the contact carrier 200. Although not illustrated, thecontact carrier 200 may further include one or more second powerterminals located on a second end 220 of the contact carrier 200.Although illustrated as having four power terminals 210, the connector115 may include any number of power terminals and second powerterminals, for example one power terminal and one second power terminal,two power terminals and two second power terminals, three powerterminals and three second power terminals, four power terminals andfour second power terminals, five power terminals and five second powerterminals, etc. In some embodiments, the power terminals 210 areelectrically connected to the load 110 while the second power terminalsare electrically connected to the power supply 105.

FIGS. 3-7 illustrate the contact carrier 200 according to someembodiments of the application. As illustrated in the exploded view ofFIG. 3, the contact carrier 200 includes a shell 300, a cover 305, oneor more connector contacts 310, one or more contact cores 315, one ormore transformer windings 320, one or more sensors 325, and electronicassembly 330, and an antenna 335. The shell 300 is formed of anon-conductive material, such as but not limited to, a plastic material.The cover 305 is also formed of a nonconductive material, such as butnot limited to, a plastic material. The shell 300, in conjunction withthe cover 305, houses various components of the contact carrier 200. Theone or more connector contacts 310 provide an electrical connectionbetween the power terminals 210 and the second power terminals. Thecontact cores 315 are configured to receive the respective connectorcontacts 310. The contact cores 315 include transformer windings 320integrated into the contact cores 315. The transformer windings 320sense current travelling through the respective connector contacts 310.In some embodiments, a three-phase power supply may be monitored usingtwo sets of transformer windings 320.

FIGS. 8-10 illustrate a contact transformer (CT) module 400 includingthe contact 310, the contact core 315, and the transformer winding 320.As illustrated, the contact core 315 receives the respective contact310. Additionally, as illustrated, the transformer winding 320 isintegrated (e.g., wrapped around) the contact core 315. In someembodiments, the transformer windings 320 are a high turns-ratio linearwindings wound around the respective cores 315. By spreading thetransformer windings 320 along the length of the respective cores 315,current can be accurately sensed without exceeding the availablegeometry constraints of the contact carrier 200. The amount of CTmodules 400 contacted within the shell 300 of the contact carrier 200corresponds to the amount of power terminals of the contact carrier 200.In other embodiments, the transformer winding 320 may be a magnetic corewinding having special geometry to fit around the core 315 and/or in theshell 300.

FIGS. 11 and 12 illustrate the CT module 400 without the contact 310. Asillustrated, the CT module 400 further includes a contact opening 405and wind guide ribs 410. The contact opening 405 is configured toreceive the contact 310. The wind guide ribs 410 may be used to guidethe transformer winding 320.

As illustrated in FIGS. 8-12, the CT module 400 further includes asensor slot 415. The sensor slot 415 is configured to couple arespective sensor 325 to the CT module 400. In some embodiments, the oneor more sensors 325 are configured to sense a voltage between the powersupply 105 and the load 110 and/or a temperature of the contact 310. Asillustrated, in some embodiments, the sensors 325 are clips configuredto couple to the sensor slots 415 of the CT modules 400. In someembodiments, the sensors 325 thermistors, thermocouples, RTDs, or anysimilar sensor.

FIG. 13 illustrates the CT module 400 according to some embodiments ofthe application. In such an embodiment, the CT module 400 includes ashield 420. The shield 420 covers the transformer windings 320. In someembodiments, shielding the windings 320 improves current sensing.

FIGS. 14 and 15 illustrate the electronic assembly 330 and antenna 335contained within the shell 300 of the contact carrier 200. Asillustrated, in some embodiments, the electronic assembly 330 andantenna 335 are located between the CT modules 400, and thus thecontacts 310. Such a placement may eliminate interference whileproviding easy connection to the transformer windings 320 and sensors325. In some embodiments, in addition to sensors 325, the electronicsassembly 330 may include, or be connected to, additional sensors. Insuch an embodiment, the additional sensors may include an additionaltemperature sensor configured to sense a temperature central to theconnector core. Also in such an embodiment, the additional sensors maysense the temperature of one or more various points of the contactcarrier 200. Also in such an embodiment, the additional sensor mayinclude an ambient sensor for sensing a temperature external the contactcarrier 200.

In the illustrated embodiment, the antenna 335 is routed from theelectronic assembly 330 along the outside wall of the shell 300. In someembodiments, the antenna 335 may be held in place by one or more slotsin support ribs and/or holes adjacent the outside wall. The antenna 335may be a dipole-type antenna, a loop-type antenna, a flat chip antenna,or any other known antenna. The antenna 335 is configured to wirelesslytransmit various characteristics of the contact carrier 200. Forexample, the antenna 335 may wirelessly transmit current, voltage, andtemperature of the contact carrier 200. In some embodiments, thecharacteristics are wirelessly transmitted to one or more externaldevices. In some embodiments, rather than, or in addition to, antenna335, the contact carrier 200 may include an input/output port. In suchan embodiment, the various characteristics described above may betransmitted via physical coupling.

FIGS. 16 and 17 illustrate biased transformer windings 500 according toanother embodiment of the application. As illustrated, the biasedtransformer windings 500 may be integrated into, or around, the CTmodules 400. In such an embodiment, the biased transformer windings 500may be a Ragowski helical coil or a biased winding toroid. Such anembodiment may enable the placement of the CT modules 400 intogeometries that are typically too small for a full transformer winding.

Thus, the application provides, among other things, an improved methodand system for sensing various characteristics of an electronic powerconnector. Various features and advantages of the application are setforth in the following claims.

What is claimed is:
 1. An electronic power connector comprising: a contact configured to electrically connect a power supply to a load; and a contact core configured to receive the contact, the contact core including a transformer winding wrapped around the contact core, the transformer winding configured to sense a current.
 2. The electronic power connector of claim 1, wherein the electronic power connector further comprises a sensor.
 3. The electronic power connector of claim 2, wherein the sensor is a voltage sensor.
 4. The electronic power connector of claim 2, wherein the sensor is a temperature sensor.
 5. The electronic power connector of claim 2, wherein the sensor slot is located at a first end of the contract core.
 6. The electronic power connector of claim 1, further comprising a sleeve configured to cover the contact and the contact core.
 7. The electronic power connector of claim 1, wherein the power supply is a single-phase power supply having a voltage of approximately 100 volts AC to approximately 240 volts AC.
 8. The electronic power connector of claim 1, wherein the power supply has a voltage of at least one selected from the group consisting of approximately 24 volts direct current, approximately 48 volts direct current, and approximately 400 volts direct current.
 9. The electronic power connector of claim 1, wherein the power supply is a three-phase power supply having a voltage of approximately 208 volts AC to approximately 600 volts AC.
 10. The electronic power connector of claim 1, further comprising an antenna configured to transmit an electrical characteristic.
 11. A power connector comprising: a sleeve; a contact carrier located within the sleeve, the contact carrier includes a contact transformer module having a transformer winding wrapped around a contact core.
 12. The power connector of claim 11, wherein the transformer winding is configured to sense a current.
 13. The power connector of claim 11, wherein the contact transformer module further includes a sensor slot configure to receive a sensor.
 14. The power connector of claim 13, wherein the sensor is a voltage sensor.
 15. The power connector of claim 13, wherein the sensor is a temperature sensor.
 16. The power connector of claim 11, further comprising an antenna located within the sleeve, the antenna configured to transmit an electrical characteristic.
 17. The power connector of claim 11, wherein the power supply has a voltage of at least one selected from the group consisting of approximately 24 volts direct current, approximately 48 volts direct current, and approximately 400 volts direct current.
 18. A method of sensing various characteristics of an electronic power connector, the method comprising: providing a transformer winding wrapped around a contact core; sensing, via the transformer, a first characteristic; and sensing, via a sensor, a second characteristic.
 19. The method of claim 18, wherein the first characteristic is a current.
 20. The method of claim 18, wherein the second characteristic is at least one selected from a group consisting of a voltage and a temperature. 